Mattress and mattress foundation

ABSTRACT

A mattress assembly having a mattress foundation and a mattress selectively attachable to the foundation in position shifting prohibiting relationship. The mattress has a plurality of tuftedtogether layers of differing density foamed material. The layer arranged adjacent the foundation is the most firm, while the layer spaced farthest from the foundation is the softest. A frame provided with a covering layer of foamed material arranged for contacting the mattress forms the foundation.

United States Patent 1191 1111 3,837,020

Bosch [4 Sept. 24, 1974 [54] MATTRESS AND MATTRESS FOUNDATION 3,685,063 8/1972 Morgan 5/345 R [76] Inventor: 23:25 1: tanley Primary Examiner-Paul R. Gilliam g Assistant Examiner-Andrew M. Calvert [22] Filed: May 23, 1973 Attorney, Agent, or FirmClarence A. OBrien; [21] AppL NO: 363,110 Harvey B. Jacobson [57] ABSTRACT CCll. M53 7 54 1: 1 A mattress assembly having a mattress foundation and [58] Fie'ld 3 355 R a mattress selectively attachable to the foundation in ea 5 61 B position shifting prohibiting relationship. The mattress has a plurality of tufted-together layers of differing density foamed material. The layer arranged adjacent [56] References Clted the foundation is the most firm, while the layer spaced UNITED STATES PATENTS farthest from the foundation is the softest. A frame 3,135,971 6/1964 Haller 5/9 R provided with a covering layer of foamed material ar- 3,319,272 ?/1967 Eller 52/123138 ranged for contacting the mattress forms the founda- 3,350,726 1 [1967 Gardner 5/3 X 3,534,417 10/1970 Boyles 5/345 R [on 6 Claims, 6 Drawing Figures PATENTEDSEPZMSH SHEET 1|! 2 Velcro Fastener 1 MATTRESS AND MATTRESS 'IFGUNDATION BACKGROUNDOF THEIINV-ENTION 1. Field of the Invention This invention relatespgenerally to a mattress assembly, and particularly to afoam covered mattress foundation and a multi-layered foam mattress selectively attachable to the foundation.

2. Description of the Prior Art It is broadlyknown to attach amattressto an associated foundation for'preventing theformer'from shifting with respect tothe latter. .Examples ofr'prior an arrangements of this kind are shown'in-U:S. Pat. 'Nos. 1,559,119, 1,642,140 and 3,135,971.

It is also known to construct a mattressfrom a plural- .ity of layers of foamed material. These layers 'may or may not all'be ofdifferentdensities,.with'the'mostconventional arrangement having "the most firm layer on top, or spaced :farthestlfrom asur'facesupportingthe mattress. An example ofsuchamattress maybe found in U.S.'Pat. No. 3,534,417, while examples of cushions using a plurality of foamed layers:arefoundinUISJ'Pat. Nos. 3,118,153 and 3,319,272. The tcushion set-outin Pat. No. 3,1 18,153 u'ses ilowdensity orsoft layersitop ,and bottomandia'hi'gh density or firm layer between the two soft layers.

SUMMARY OF THEINVENTION It is an object of the.presentinventionto provide an improved non-shifting mattress assembly.

It is another object of the presentinventionto provide a non-shifting-mattress thataffordsproper comfort and support independently ofaausers weight.

It is yet another object of the presentinventionto provide a cushioned mattress foundationof'rigidflightweight construction.

These and other objects are achieved according to the present invention'by providinga mattress assembly having: a mattress including a plurality of layers of foamed material;.and a mattress 'foundation including a frame and a covering layer of foamed material arranged on the frame in a position whereit will contact the mattress.

The mattress assembly advantageously isefurther provided with an arrangement which permits selective attachment of the mattress .to the mattress foundation to prohibit the mattress from shifting relative to the foundation.

According to apreferred embodiment'of a mattress according to the present invention, the plurality of layers of foamed materialare three layers oftpolyurethane foam, each layer being of a differentdensity'from the other layers. A layer arranged adjacent the foundation is preferably the most firm of the three layers, and a layer spaced farthest from the foundation is softest. These three layers may be tied together'and encased in a suitable tick.

A preferred embodiment of a frame for a mattress foundation according to the present invention has a rigid framework formed from a plurality of slats and spaces, and a perforatedsheet constructed from a'hard, rigid material affixed to -the'framework and covering a planar surface of same. The covering layer maybe mounted on the framework covering sheet.

These together with other objects and advantages which will become subsequently apparent reside in the details of construction and operation as more fully hereinafter described and claimed, reference being had to the accompanying drawings forming a part hereof, wherein like numerals refer to like parts throughout.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view, partly broken away, showing a mattress assembly according to the present invention.

FIG. 2 is a sectional view, partly broken away, taken generally along the line 2-2 of FIG. '1.

FIG. 3 is a sectional view, partly broken away, taken ggenerally along the line 3-3 of FIG. 1.

DESCRIPTION OF THE PREFERRED EMBODIMENTS FIGS. 1 to 3 of the drawings show a mattress assembly 10 according to the present invention. This assembly 10 includes a mattress l2 formed-from a plurality, three being shown, of Iayerszl4, l6, and 18 constructed ofa formed material. Any suitable, known foamed material, such as polyurethane, of various densities may be used to constructthe mattress layers. Although three layers are shown in the illustrated embodiment of a mattress 12 according to the present invention, his to be understood that the exact number of layers is not critical to the invention. Mattressassembly 'l0 also has amattress foundation 20 including a frame 22 and a covering layer 24 of foamed material arranged on frame 22 so as to contact mattress 12.

As stated above, each layer l4, l6, and 18 isof a different density from the other layers, with layer '18, arranged adjacent foundation 20 when the mattress and foundation are assembled, the most firm of the layers, and layer 14, spaced farthest from foundation 20, the softest. Polyurethane foam sold by the Carpenter company with the designations R 17, R 28, and R45 has been found suitable for layers 14, 16, and 18, respectively. Since layer 14 is the softest and layer 18 the most firm, middle layer 16 is of course between the two outer layers in firmness, and advantageously of a medium firmness rating. Tufting 26 (FIG. 4) ties together the three layers 14, 16, and 18, and a, for'example, conventional muslin tick generally designated by the reference numeral 28 may encase the tufted layers forming mattress 12, while an outer tick 28', which may alsoibe muslin, encases foam and inner tick 28, and is attached to tick 28 as by pieces 29 conventionally attached to edges of ticks 28 and 28. In this manner, the entire unit is locked together, thus preventing shifting, while tufting 26 is concelaed by tick 28. Nylon has been found a suitable material for tufting 26. Although tufting 26 has been indicated as constructed from nylon and ticks 28, 28' from a muslin fabric, it is to be understood that these are examplary only, and any suitable, known materials may be used in these applications.

It is also to be understood that the thickness of the various layers forming mattress 12 are optional, but thicknesses of 1% inch, 3 inches, and 3 inches have been used satisfactorily for layers l4, l6, and 18, re spectively.

Frame 22 of mattress foundation 20 has a rigid. lightweight framework 30 formed from a plurality of suitably arranged spacers 32 and slats 34, 36, 38, 40, 42, and 44. As can be readily seen from FIGS. 2 and 3 of the drawings, slats 34 form lower side rails of framework 30, while slats 36 are upper side rails arranged generally parallel to slats 34. Slat 38 is a central column forming a support for upper framework structure to be described below, and slats 40 and 42 are lower and upper end rails engaging side rail slats 34 and 36. Slats 44 are top slats which form an upper surface to framework 30. Although any desired number of slats 44 may be used, thirteen slats 2 inches by 541 inches in cross section have been found satisfactory. A perforated sheet 46 of, for example, plywood, and the like, is affixed to framework 30 and covers a planar surface of same to form a deck. Wallboard has also been found satisfactory for sheet 46, and generally speaking this sheet may be formed from any suitable, known, hard, rigid material in the form of a planar member. The perforations permit frame 22 to breath. As can readily be appreciated from FIGS. 2 and 3 of the drawings, spacers 32 are arranged between the various side end rails for rigidifying the structure.

Covering layer 24, which is advantageously constructed from a foamed material such as polyurethane of substantially the same density as the adjacent mattress layer 18, is mounted on the framework covering sheet 46 in a conventional manner, and is covered with a suitable tick 48 which extends down onto framework 30. The ticks 28 and 48 may be constructed in a conventional manner, and tick 48 attached to framework 30 as by conventional fasteners.

A wide band of, for example, a conventional fabric is designated by the reference numeral 50 in FIGS. and 6 of the drawings. See also FIGS. 1 and 2. This band 50 is connected to mattress 12 as by conventional stitching to tick 28 in the manner shown in FIG. 6 of the drawings, and is arranged extending transversely of mattress l2. Fasteners 52 (FIG. 2) formed by fastener elements 54 arranged at free ends of band 50 and fastener elements 56 provided on tick 48 of foundation permit the selective attachment of mattress 12 to mattress foundation 20 so as to prohibit mattress 12 from shifting relative to foundation 20. While any suitable, known cooperating fastener elements may be used for elements 54 and 56, those fastening elements sold under the trade-mark Velcro are illustrated in FIG. 5. By attaching band 50 to mattress 12 in the manner shown in FIG. 6, space is provided along the sides of mattress 12, as well as the ends thereof, to allow bed linens, blankets, and the like, to be tucked under mattress 12 in the conventional manner. FIG. 6, as well as FIG. 1, give an indication of the spacing of tufting 26 in mattress 12. A spacing, of for example, 7 inches at the ends and 5 inches along the sides has been successfully used with a standard size mattress.

As can be readily understood from the above description and from the drawings, tufting 26 provides a nonshifting mattress having band 50 which permits the mattress to cooperate with mattress foundation 20 to provide a non-shifting mattress assembly. Further, light-weight framework provides a base for a frame 22 suitable for cooperation with the particular multilayered mattress 12 according to the present invention to form a simple, rugged, light-weight assembly. It should be mentioned that the corners of the various elements forming framework 30 are rounded as is conventional and can be appreciated from FIG. 1 of the drawings.

The foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in' the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.

What is claimed as new is as follows:

1. A mattress assembly, comprising, in combination:

a. a mattress including a plurality of layers of resilient materials, the mattress layers being three layers of a foamed material, each layer being of a different density from the other layers, with a layer arranged adjacent. the foundation being the most firm and a I layer spaced farthest from the foundation the soft est, tufting tying together the three layers, and a tick encasing the tufted layers;

b. a mattress foundation including:

i. a frame; and

ii. a covering layer of resilient material and arranged on the frame for contacting the mattress; and

c. the mattress assembly further including means for selectively attaching the mattress to the mattress foundation and prohibiting the mattress from shifting relative to the mattress foundation, the means for attaching including a band connected to the mattress and arranged extending transversely of the mattress, and cooperating fastener elements affixed to the band and mattress foundation.

2. A structure as defined in claim 1, wherein the frame includes a rigid framework and a perforated sheet constructed from a hard, rigid material affixed to the framework and covering a planar surface of same, and the covering layer is constructed from a foamed material of substantially the same density as the adjacent mattress layer and is mounted on the framework covering sheet.

3. A mattress assembly, comprising, in combination:

a. a mattress including a plurality of layers of resilient materials, the mattress layers being three layers of a foamed material, each layer being of a different density from the other layers, with a layer arranged adjacent the foundation being the most firm and a layer spaced farthest from the foundation the softest, tufting tying together the three layers, and a tick encasing the tufted layers; and

b. a mattress foundation including:

i. a frame; and ii. a covering layer of resilient material and arranged on the frame for contacting the mattress.

4. A mattress assembly, comprising, in combination:

aL'a mattress including a plurality oflayers of resilient materials; and b. a mattress foundation including:

i. a frame, the'frame including a rigid framework and a perforated sheet constructed from a hard, rigid material affixed to the framework and covering a planar surface of same, the covering layer being constructed from a foamed material mounted on the framework covering sheet; and

ii. a covering layer of resilient material and arranged on the frame for contacting the mattress.

5. A structure as defined in claim 4, wherein the mattress assembly further includes means for selectively attaching the mattress to the mattress foundation and the band and mattress foundation. 

1. A mattress assembly, comprising, in combination: a. a mattress including a plurality of layers of resilient materials, the mattress layers being three layers of a foamed material, each layer being of a different density from the other layers, with a layer arranged adjacent the foundation being the most firm and a lAyer spaced farthest from the foundation the softest, tufting tying together the three layers, and a tick encasing the tufted layers; b. a mattress foundation including: i. a frame; and ii. a covering layer of resilient material and arranged on the frame for contacting the mattress; and c. the mattress assembly further including means for selectively attaching the mattress to the mattress foundation and prohibiting the mattress from shifting relative to the mattress foundation, the means for attaching including a band connected to the mattress and arranged extending transversely of the mattress, and cooperating fastener elements affixed to the band and mattress foundation.
 2. A structure as defined in claim 1, wherein the frame includes a rigid framework and a perforated sheet constructed from a hard, rigid material affixed to the framework and covering a planar surface of same, and the covering layer is constructed from a foamed material of substantially the same density as the adjacent mattress layer and is mounted on the framework covering sheet.
 3. A mattress assembly, comprising, in combination: a. a mattress including a plurality of layers of resilient materials, the mattress layers being three layers of a foamed material, each layer being of a different density from the other layers, with a layer arranged adjacent the foundation being the most firm and a layer spaced farthest from the foundation the softest, tufting tying together the three layers, and a tick encasing the tufted layers; and b. a mattress foundation including: i. a frame; and ii. a covering layer of resilient material and arranged on the frame for contacting the mattress.
 4. A mattress assembly, comprising, in combination: a. a mattress including a plurality of layers of resilient materials; and b. a mattress foundation including: i. a frame, the frame including a rigid framework and a perforated sheet constructed from a hard, rigid material affixed to the framework and covering a planar surface of same, the covering layer being constructed from a foamed material mounted on the framework covering sheet; and ii. a covering layer of resilient material and arranged on the frame for contacting the mattress.
 5. A structure as defined in claim 4, wherein the mattress assembly further includes means for selectively attaching the mattress to the mattress foundation and prohibiting the mattress from shifting relative to the mattress foundation.
 6. A structure as defined in claim 5, wherein the means for attaching includes a band connected to the mattress and arranged extending transversely of the mattress, and cooperating fastener elements affixed to the band and mattress foundation. 